Suspended ceiling panel system for residential and commercial buildings

ABSTRACT

A suspended ceiling panel system includes a grid system that includes a main beam and a cross beam. The suspended panel system also includes a panel which includes a grid molding and a trim molding. The grid molding is disposed upon at least one of the main beam and the cross beam of the grid system. The trim molding is attached to the grid molding such that a portion of the main beam or the cross beam is disposed between the trim molding and the grid molding.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/610,516, filed on Mar. 14, 2012.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to a suspended ceiling panel system forresidential and commercial buildings. More particularly, the inventionrelates to a suspended ceiling panel system that includes a panel formedfrom a grid molding and a trim molding that is in turn mounted onT-shaped frame members that are joined to create a grid. The ceilingpanels are designed to accommodate various ceiling structures such assprinkler heads, exit signs, heating ventilation and air conditioningductwork and lights. The suspended ceiling panel system is easy toassemble and results in a uniform appearance that is aestheticallypleasing to the eye. Moreover, the suspended ceiling panel system of thepresent invention is easy to install and provides increased insulationcharacteristics over prior art suspended ceiling panel system, and alsoprovides increased noise reduction and/or reduces sound transmissionthrough the ceiling panel, while still providing fire resistance,bacteria resistance and moisture resistance.

2. Background Art

Many types of buildings, such as commercial and government officebuildings, utilize suspended ceilings. Suspended ceilings typicallyinclude a suspension grid system and acoustical panels. The grid system,for example, may be used to suspend the panels from the overheadbuilding structure generally in a single plane. The suspended ceiling isformed by attaching the grid to hanger wires that are in turn attachedto the building structure, and thus the load of the grid system with itsassociated lighting components, airflow distribution components, andacoustical panels is transferred to the building structure by the hangerwires. A variety of types of lay-in ceiling panels are available for usewith exposed grids including cast, water felted, fiberglass, gypsum, andmetal.

Grid systems may be formed using inverted T-shaped main beams, invertedT-shaped crossbeams, and hangars. The main beams are metal framingmembers that are hung from the hangars. The cross beams typically aremetal framing members snap fitted to the main beams, perpendicularthereto.

One popular variant of the suspended ceiling is a prior art suspendedceiling system that utilizes a grid frame that includes invertedT-shaped frame members for the main beams and cross beams. The framemembers are configured in such a manner to form a suspended grid thatincludes multiple grid elements, which are known as modules. Thesemodules may be provided in any practicable size, with about 24 in.squares and about 24 in.×48 in. rectangles being a common module size.The suspended ceiling is formed by installing ceiling panels into themodules such that each edge portion of the bottom surface of each panelis supported by an inverted T-bar main beam or cross beam. The prior artsuspended ceiling panel system is completed by incorporating requiredutilities into the system such as sprinkler heads, heating, ventilationand air conditioning (HVAC) elements, and lighting fixtures. Suspendedceiling panel systems, for example, may provide decoration, lightreflection, and/or masking of utility infrastructure.

A prior art system for suspending ceiling panels have been popular forboth commercial and residential buildings. These prior art systems allowthe installation of a ceiling panel, which is typically minimallyacoustically absorbent and is aesthetically pleasing. These prior artceiling systems, moreover, can be relatively quickly and easilyinstalled. Prior art suspended ceiling panel systems are particularlydesired for hiding pipes, wiring, and air duct systems that are commonin many buildings.

In many applications, it is desirable that a suspended ceiling panelsystem provide significant degree of acoustic insulation or damping. Inparticular, in an office environment where speech privacy is important,it is desirable to limit the amount of sound that can otherwise travelthrough the ceiling from one office to an adjacent office, or from oneroom to an adjacent room.

Utilizing ceiling panels made from sound absorbing materials can providea measure of acoustic insulation in a suspended ceiling system. Forexample, U.S. Pat. No. 5,832,685 to Hermanson is directed to aself-supporting, sound absorbing, interior surface panel as well as asuspended ceiling module comprising a support structure, such as a T-bargrid, and a panel, which could be supported within the module in eithertegular or coffered orientation.

Using sound absorbing ceiling tiles alone, however, does not provideacoustic insulation of modules of a suspended ceiling system wherelighting fixtures or other utilities, such as signs, airflow ducts orsprinkler heads are installed. To this end, various additional deviceshave been introduced to providing acoustic insulation with respect tothose fixtures.

In addition, prior art suspended ceiling systems utilize insulationcomponents that typically are not resistant to bacteria and/or moistureand therefore, can provide an environment for bacterial infestation andpropagation that can lead to discoloration or transmission of thebacterial component into the room. When the prior art suspended ceilingpanel systems are utilized in an environment that needs to be maintainedsterile, such as a hospital operating room or an outpatient surgicaloperating room, the existence of such a bacterial component can beespecially problematic.

In view of these developments, there remains a need for an improvedsuspended ceiling panel system that can be utilized in connection withstandard inverted T-shaped main beams and cross beams, and whichprovides accommodation for various ceiling structures such as sprinklerheads, exit signs, heating ventilation and air conditioning ductwork andlights. Moreover, there also remains a need for an improved suspendedceiling panel system that is easy to assemble and has a uniformappearance that is aesthetically pleasing to the eye. Furthermore, therealso remains a need for an improved suspended ceiling panel system thatprovides better insulation characteristics over the prior art suspendedceiling panel systems, and also provides better noise reduction and/orreduced sound transmission through the ceiling panel while stillproviding fire resistance, bacterial resistance and moisture resistance.

SUMMARY OF THE INVENTION

Objectives of the present invention include providing a suspendedceiling panel system for residential and commercial buildings thataccommodates various ceiling structures such as sprinkler heads, exitsigns, heating ventilation and air conditioning ductwork, lights, andthe like.

A further objective of the present invention is to provide a suspendedceiling panel system for residential and commercial buildings that iseasy to assemble, has a uniform appearance that is aestheticallypleasing to the eye, and that obscures the main beams and cross beams ofthe grid system.

Yet another objective of the present invention is to provide a suspendedceiling panel system for residential and commercial buildings thatdemonstrates improved insulation characteristics.

Still another objective of the present invention is to provide asuspended ceiling panel system for residential and commercial buildingshaving improved noise reduction properties resulting in reduced soundtransmission through the ceiling panel and still provides fireresistance, bacterial resistance and moisture resistance.

These objectives and advantages are obtained by the suspended ceilingpanel system, comprising: a grid system which includes a main beam and across beam; a panel which includes a grid molding and a trim molding;the grid molding disposed upon at least one of the main beam and thecross beam of the grid system; and the trim molding attached to the gridmolding such that a portion of the main beam or the cross beam isdisposed between the trim molding and the grid molding.

These objectives and advantages are also obtained by the method ofassembly of a suspended ceiling panel system for residential andcommercial buildings, said method comprising the steps of: providing agrid system which includes a main beam and a cross beam; providing apanel which includes a grid molding and a trim molding; disposing thegrid molding on at least one of the main beam and the cross beam of thegrid system; and attaching the trim molding to the grid molding suchthat a portion of the main beam or the cross beam is disposed betweenthe trim molding and the grid molding.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The preferred embodiment of the present invention, illustrative of thebest mode in which applicants have contemplated applying the principles,is set forth in the following description and is shown in the drawings,and is particularly and distinctly pointed out and set forth in theappended claims.

FIG. 1 is a fragmentary bottom perspective view of a prior art suspendedceiling panel system, showing the frame members consisting of main beamsand cross beams forming the grid and showing the panels of the ceilingpanel system disposed onto the upper surfaces of the frame members;

FIG. 2 is a top perspective view of a ceiling panel of the ceiling panelsystem of the present invention, showing the grid moldings extendingalong the four sides of the panel and showing the trim molding attachedto the bottom portion of the grid molding of the of the panel;

FIG. 2A is a bottom perspective view similar to the view shown in FIG.1, showing the trim molding attached to the bottom portion of the gridmolding with the cloth covering of the trim molding removed and showingthe stone wool insulation seated within the grid molding;

FIG. 3 is an interior perspective view of a single side of the gridmolding and trim molding with the stone wool insulation and othercomponents of the ceiling panel removed, showing the attachment means ofthe trim molding to the grid molding of the ceiling panel system;

FIG. 4 is a cross sectional view of the trim molding and the gridmolding prior to installation of the trim molding onto the grid molding,showing the lower leg of the grid molding extending downwardly towardthe interior vertical member of the trim molding;

FIG. 5 is a fragmentary cross sectional view of adjacent grid moldingsof adjacent ceiling panels mounted on an inverted T-shaped main beam ofan existing grid system, showing the grid molding seated on the mainbeam and including stone wool insulation, an LED light, and showing thetrim molding attached to the lower leg portion of the grid molding, andalso showing the cloth formed over the trim molding;

FIG. 6 is a top exploded perspective view of alternate configurations ofthe ceiling panels that can be incorporated into the ceiling panelsystem of the present invention, showing panel configurations forlighting, exit signs, sprinkler heads, and duct work that are easilyincorporated into the ceiling panel system of the present invention;

FIG. 7 is a bottom exploded view of the alternate configurations of theceiling panels of the ceiling panel system of the present inventionshown in FIG. 6; and

FIG. 8 is a fragmentary cross sectional view of a ceiling panel of theceiling panel system of the present invention, showing the grid moldingthat surrounds the insulation and an LED light bar seated on theinverted T-shaped main beam and including the trim molding attached tothe grid molding, and showing the trim molding covered by cloth.

Similar numerals referred to similar parts throughout the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In order to better understand the structure, assembly, and operation ofthe preferred embodiment suspended ceiling panel system of the presentinvention, the structure and installation of a prior art suspendedceiling panel system will be described in detail below.

Turning now to FIG. 1, a prior art suspended ceiling panel system 10includes a grid formed by a frame member 12, which may be main beams 30or cross beams 39 as previously described above. Frame members 12 thatform main beam 30 and cross beams 39 are inverted T-shaped members.Ceiling tiles 18 are positioned and supported by the grid formed byframe members 12.

Where frame members 12 are inverted T-shaped members, ceiling panels 18are installed such that an edge portion of the bottom surface of eachceiling tile rests on a cross bar portion 34 of an inverted T-shapedframe member. Preferably, the cross bar portion is disposed in a planegenerally parallel to a plane defined by ceiling panel 18. Suspendedceiling system 10 also may include lighting fixture 20 and HVAC elements(not shown). Lighting fixture 20 is installed in desired locations inthe grid formed by frame members 12. Each ceiling panel 18 and lightfixture 20 is generally about two feet by about two feet in largestfootprint, although in an alternate embodiment a rectangular shapedfootprint of about two feet by about four feet in dimension may be usedfor the ceiling panel and the light fixture.

Having now described the structure of prior art suspended ceiling panelsystem 10, the installation of the prior art suspended ceiling panelsystem will now be described below. Frame members 12 are attached to thestructure of the building by wires (not show). As set forth above, thewires hang down a distance from the ceiling structure and suspend framemembers 12 in a single plane. Ceiling panels 18 are then disposed intoframe members 12 in a manner generally well known to those having skillin the relevant art.

Prior art suspended ceiling panel system 10 provides noise reductioninside the space below the ceiling panel by allowing sound to passthrough the panel, decelerate, then reflect and disperse off the ceilingof the building. This slightly reduces noise in the space below priorart suspended ceiling panel system 10, but allows the sound to passthrough the panels, which creates sound transmission issues. This isespecially true when the space above prior art suspended ceiling panelsystem 10 is used as a plenum return and is open to the surroundingspaces, thereby allowing sound transmitted through the ceiling panel tobe transmitted into the adjacent rooms and spaces.

As described above, prior art suspended ceiling systems utilize panels18 that typically are not resistant to bacteria and/or moisture and,therefore, can provide an environment for bacterial infestation andpropagation that can potentially lead to discoloration or transmissionof the bacterial component into the room. When suspended ceiling panelsystem 10 is being utilized in an environment that needs to bemaintained sterile, such as a hospital operating room or an outpatientsurgical operating room, the existence of such a bacterial infestationcan be especially problematic.

Moreover, prior art suspended ceiling panel system 10 must be adaptedfor inclusion of HVAC ducts, vents, lights, fire sprinkler systems andthe like and therefore requires additional time to install and/orassemble the finished ceiling panel system.

In view of this, there remains a need for an improved ceiling panelsystem that can be utilized in connection with standard invertedT-shaped main beams and cross beams, and which provides accommodationfor various ceiling structures such as sprinkler heads, exit signs,heating ventilation and air conditioning ductwork and lights. Moreover,there also remains a need for an improved suspended ceiling panel systemthat is easy to assemble and has a uniform appearance that isaesthetically pleasing to the eye. Furthermore, there also remains aneed for an improved suspended ceiling panel system that provides betterinsulation characteristics over prior art suspended ceiling panelsystems, and which also provides better noise reduction and/or reducessound transmission through the ceiling panel while still providing fireresistance, bacterial resistance and moisture resistance.

These problems are overcome by the suspended ceiling panel system of thepresent invention, which is described in detail below.

A preferred embodiment suspended ceiling panel system of the presentinvention is shown generally at reference numeral 110 in FIGS. 2-8 andwill now be described in detail below. With particular reference toFIGS. 2 and 2A, suspended ceiling panel system 110 of the presentinvention is formed from a plurality of generally square panels 111having dimensions of approximately two feet by two feet (only a singlepanel is shown). Panel 111 includes a grid molding 112 located on eachof the four sides of the panel. Grid molding 112 is preferably formedfrom plastic, but may also be formed from other sufficiently rigidmaterial such as metal, alloy, and the like. Grid moldings 112 aremitered at 45 degrees at each of their ends and are attached to oneanother by a means generally well known in the art, such as by adhesiveor thermal welding, to form a generally open-centered square structure.Panel 111 includes a trim molding 114 on each of the four sides of thepanel. Trim molding 114 is preferably formed from plastic, but may alsobe formed from other sufficiently rigid material such as metal, alloy,and the like. Trim moldings 114 are also mitered at 45 degrees at eachof their ends and are attached to one another by a means well known inthe art, such as by adhesive or thermal welding, to form a generallyopen-centered square structure. Panel 111 also includes insulation 116that is disposed into an opening 115 formed by grid moldings 112.Insulation 116 is preferably a stone wool insulation having an overallthickness equivalent to the height of grid molding 112.

With particular reference to FIGS. 3-5, grid molding 112 has a generallyC-shaped cross section including a vertical member 138, a top member 146and a bottom member 136. A leg 134 extends generally downwardly from theinterior end of bottom member 136. An interior web 144 is formed nearbottom member 136 and extends perpendicularly away from vertical member138. Web 144 is equivalent in length to both top member 146 and bottommember 136. An interior top step 148 is formed at the junction of topmember 148 and vertical member 138. An interior bottom step 142 isformed at the junction of web 144 and vertical member 138. Insulation116 is disposed between web 144 and top member 146 and against interiorsteps 148 and 142 (FIG. 5) to hold the insulation in space in panel 111.A magnet 122 is disposed between web 144 and bottom member 136. An LEDlight 120 is also disposed between web 144 and bottom member 136.Vertical member 138 of grid molding 112 may optionally be formed with arecess 140 as shown in FIG. 5. Recess 140 is only necessary whereinverted T-shaped main beam 30 includes top bulb 33.

Trim molding 114 has a generally 9-shaped cross-section rotated 90degrees and includes an interior vertical member 130 a bottom member 152and an outer tubular member 150. Outer tubular member 150 is formed witha square shaped tube 132 into which a metal square-shaped column isdisposed. A cloth 118 is disposed over trim moldings 114 and forms acloth bottom covering for panel 111. Trim molding interior verticalmember 130 rests against leg 134 of grid molding 112 and metal column124 of the trim molding is attracted to magnet 122 of the grid moldingto magnetically hold the trim moldings into place beneath the gridmoldings.

Optionally, trim molding 114 interior vertical member 130 can be formedwith a bulb 128 as shown in FIG. 8. In this configuration, leg 134 ofgrid molding 112 is formed with a socket 126. Trim molding bulb 128 isdisposed into socket 126 to mechanically hold the trim moldings intoplace beneath the grid moldings.

Turning now to FIGS. 6 and 7, configurations of panel 111 are shown inexploded view for incorporating airflow ductwork 200, lighting fixtures202, signs 204, sprinkler heads 206, exit signs 208 and light panels210. Incorporation of the various fixtures is made simple by providingpre-cut insulation inserts 116 that allow passage of the variousfixtures through the stone wool insulation.

Having now described the structure of suspended ceiling panel system 110of the present invention, assembly of the ceiling panel system onto astandard inverted T-shaped main beam will now be described in detailbelow.

The grid system including inverted T-shaped main beams 30 and crossbeams 39 are assembled in a manner well known to those having skill inthe art. In an application where an existing grid system already exists,this step can be eliminated. Grid moldings 112 including insulation aredisposed into the grid system with bottom members 136 of the gridmoldings resting on flanges 34 of T-shaped main beams 30 and cross beams39. Trim moldings 114, including cloth covers 118 are then mechanicallyor magnetically fastened onto grid moldings 112 as described above.

Suspended ceiling panel system 110 of the present invention accommodatesvarious ceiling structures and/or fixtures, such as sprinkler heads,exit signs, heating ventilation and air conditioning ductwork andlights. Moreover, suspended ceiling panel system 110 of the presentinvention is easy to assemble and has a uniform appearance followinginstallation that is aesthetically pleasing to the eye. Furthermore,suspended ceiling panel system 110 of the present invention providesbetter insulation characteristics over prior art suspended ceiling panelsystems, such as the one described above, and also provides better noisereduction and/or reduces sound transmission through the ceiling panelbetter than prior art suspended ceiling panel systems, yet stillprovides fire resistance, bacteria resistance and moisture resistance.Suspended ceiling panel system 110 of the present invention provides aninsulation barrier having an R factor of 8.4. Suspended ceiling panelsystem 110 of the present invention also provides a noise reductioncoefficient of 1 evenly above 100 hertz. Suspended ceiling panel system110 of the present invention further provides a sound transmissioncoefficient of approximately 40. This is accomplished because suspendedceiling panel system 110 of the present invention allows for a fullfrequency range of sound absorption in the space below the suspendedceiling panel system, but also traps the sound in the panel itself,creating a sound transmission barrier between the adjacent rooms andspaces.

Suspended ceiling panel system 110 of the present invention is adaptedfor use with lighting fixtures, duct work, signs, sprinkler systems, andlighting, yet still provides fire resistance, bacteria resistance,moisture resistance, noise reduction and minimizes noise transfer whileremaining aesthetically pleasing to the eye while obscuring the mainbeams and cross beams of the grid system. Moreover, suspended ceilingpanel system 110 of the present invention is easy to install on existingT-shaped main beams and cross beams and still provides a uniformappearance.

It is contemplated that the suspended ceiling panel system of thepresent invention could be utilized in conjunction with other types ofgrid systems utilizing other than inverted T-shaped main members,without changing the overall concept or operation of the presentinvention. It is additionally contemplated that other types of ceilingstructures and/or fixtures could be utilized in conjunction with theceiling panel system of the present invention without changing theoverall concept or operation of the present invention. Furthermore, itis contemplated that other dimensions of the ceiling panel could beutilized, such as one foot by one foot, or two foot by four foot,without changing the overall concept or operation of the presentinvention. It is also contemplated that other types of fabric could beused in conjunction with the suspended ceiling panel system of thepresent invention, without changing the overall concept or operation ofthe present invention. It is also contemplated that other types ofinsulation could be utilized in conjunction with the suspended ceilingpanel system of the present invention without changing the overallconcept or operation of the present invention.

Accordingly, the suspended ceiling panel system for residential andcommercial buildings of the present invention is simplified, provides aneffective, safe, inexpensive and efficient structure and method whichachieves all the enumerated objectives, provides for eliminatingdifficulties encountered with prior art system for suspending ceilingpanels, and solves problems and obtains new results in the art.

In the foregoing description, certain terms have been used for brevity,clearness and understanding; but no unnecessary limitations are to beimplied therefrom beyond the requirements of the prior art, because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. Moreover, the present invention has been described withreference to exemplary embodiments. It shall be understood that thisillustration is by way of example and not by limition, as the scope ofthe invention is not limited to the exact details shown or described.Potential modifications and alterations will occur to others upon areading and understanding of this disclosure, and it is understood thatthe invention includes all such modifications and alterations andequivalents thereof.

Having now described the features, discoveries and principles of theinvention, the manner in which the suspended ceiling panel system forresidential and commercial buildings of the present invention is usedand installed, the characteristics of the construction, arrangement andmethod steps, and the advantageous, new and useful results obtained; thenew and useful structures, devices, elements, arrangements, process,parts and combinations are set forth in the appended claims.

What is claimed is:
 1. A suspended ceiling panel system, comprising: agrid system which includes a main beam and a cross beam; a panel whichincludes a grid molding and a trim molding; said grid molding disposedupon at least one of said main beam and said cross beam of said gridsystem; and said trim molding attached to said grid molding such that aportion of said main beam or said cross beam is disposed between saidtrim molding and said grid molding.
 2. The suspended ceiling panelsystem for residential and commercial buildings of claim 1, wherein saidpanel further comprises insulation disposed adjacent said grid molding.3. The suspended ceiling panel system for residential and commercialbuildings of claim 1, wherein said grid molding includes a generallyC-shaped cross section.
 4. The suspended ceiling panel system forresidential and commercial buildings of claim 1, wherein said gridmolding is formed from a material selected from the group consisting ofa plastic, a metal and an alloy.
 5. The suspended ceiling panel systemfor residential and commercial buildings of claim 1, wherein said gridmolding comprises a vertical member attached to a top member and abottom member, said grid molding being formed with at least one interiorstep.
 6. The suspended ceiling panel system for residential andcommercial buildings of claim 1, wherein said attachment of said trimmolding to said grid molding is accomplished via a magnet disposedwithin said trim molding or said grid molding.
 7. The suspended ceilingpanel system for residential and commercial buildings of claim 1,wherein said trim molding is formed from a material selected from thegroup consisting of a plastic, a metal and an alloy.
 8. The suspendedceiling panel system for residential and commercial buildings of claim1, said trim molding formed with a bulb, said bulb engaging a socketformed on said grid molding.
 9. The suspended ceiling panel system forresidential and commercial buildings of claim 1, said panel furthercomprising a fixture chosen from the group consisting of a light, anairflow ductwork, a light, a sign, a sprinkler head and an exit sign.10. The suspended ceiling panel system for residential and commercialbuildings of claim 1, wherein a fabric is disposed on said trim molding.11. A method of assembly of a suspended ceiling panel system forresidential and commercial buildings, said method comprising the stepsof: providing a grid system which includes a main beam and a cross beam;providing a panel which includes a grid molding and a trim molding;disposing said grid molding on at least one of said main beam and saidcross beam of said grid system; and attaching said trim molding to saidgrid molding such that a portion of said main beam or said cross beam isdisposed between said trim molding and said grid molding.
 12. The methodof assembly of a suspended ceiling panel system for residential andcommercial buildings of claim 11, wherein said panel further comprisesan insulation disposed adjacent said grid molding.
 13. The method ofassembly of a suspended ceiling panel system for residential andcommercial buildings of claim 11, wherein said grid molding includes agenerally C-shaped cross section.
 14. The method of assembly of asuspended ceiling panel system for residential and commercial buildingsof claim 11, wherein said grid molding is formed from a materialselected from the group consisting of a plastic, a metal and an alloy.15. The method of assembly of a suspended ceiling panel system forresidential and commercial buildings of claim 11, wherein said gridmolding comprises a vertical member attached to a top member and abottom member, said grid molding being formed with at least one interiorstep.
 16. The method of assembly of a suspended ceiling panel system forresidential and commercial buildings of claim II, wherein saidattachment of said trim molding to said grid molding is accomplished viaa magnet disposed within said trim molding or said grid molding.
 17. Themethod of assembly of a suspended ceiling panel system for residentialand commercial buildings of claim 11, wherein said trim molding isformed from a material selected from the group consisting of a plastic,a metal and an alloy.
 18. The method of assembly of a suspended ceilingpanel system for residential and commercial buildings of claim 11, saidtrim molding formed with a bulb, said bulb engaging a socket formed onsaid grid molding.
 19. The method of assembly of a suspended ceilingpanel system for residential and commercial buildings of claim 11, saidpanel further comprising a fixture chosen from the group consisting of alight, an airflow ductwork, a light, a sign, a sprinkler head and anexit sign.